Expansion joint



Oct'. 7, 1969 H. KELLMAN EXPANSION JOINT med April 1v. 196s United States Patent O "ice 3,470,662 EXPANSION JOINT Irving H. Kellman, Springvale, Maine, assignor to Sandell Manufacturing Company, Inc., Cambridge, Mass. Filed Apr. 17, 1968, Ser. No. 722,009 Int. Cl. E04d 1/36; E04c 1/34; E04b 1/68 U.S. Cl. 52--99 6 Claims ABSTRACT OF THE DISCLOSURE A weatherproof expansion joint construction for use in the building industry is provided having a first elongated anchor strip, a second elongated anchor strip and a plastic sheet defining elongated, enlarged side edges and spanning between the first and second anchor strips. The joint between the plastic Sheet and the anchor strips is a weatherproof mechanical joint and preferably a swaged connection which compresses an enlargement formed at the edges of the plastic sheet without coinpressing the sheet itself.

Background of the invention Many expansion joints are well-known in the building industry for use in making weather tight roof and wall joints. Such joints `are also used in other outdoor applications such as to Weatherproof or seal various parts of boats and the like. The joint constructions normally span between members which expand and contract with various climatic conditions, thus, the joints must be resilient while remaining waterproof at normally encountered climatic weather conditions. Use of a single plastic sheet joined to opposing side edges of an opening can cause problems during expansion as the sheet is apt to rupture at the point where joined to the edges. Metal strips have been used to form side edges of plastic sheets in the past. Commonly such metal strips `are adhesively secured to the plastic sometimes raising cost and providing for leaking conditions as where the adhesive bond is incorrectly applied or destroyed over long time periods of exposure to the atmosphere.

Summary of the invention A Weatherproof expansion joint construction is provided for use in building and like industries to seal joints against vapor, water and the atmosphere. The expansion joint construction of this invention has a first elongated anchor strip, a second elongated anchor strip and a plastic sheet defining elongated side edges and spanning between the rst yand second anchor strips. The first and second side edges each define an elongated, continuous, resiliently compressible enlargement. The first and second anchor strips each carry an elongated continuous seat with the seat of the first strip joined to the enlargement of the first side edge and the seat of the second strip joined to the enlargement of the second side edge by continuous mechanical bonds with the seats compressing the enlargements and thereby forming effective moisture, liquid and gas seals.

Preferably the seats are swaged about the enlargements without compressing the plastic sheet body which compression could cause weakening of the plastic sheets. In the preferred embodiment, the seat defines a generally circular cross section as do the enlargements. Due to the 3,470,662 Patented Oct. 7, 1969 use of the mechanical bond, no extraneous bonding adhesive need be used.

The expansion joint constructions of this invention are particularly suitable in the building industry as roof and wall expansion joint constructions. Such constructions are inexpensive, easy to fabricate and have extremely long life spans when exposed to conventional atmospheric conditions.

Brief description of the drawings The above yand other features and advantages of the present invention will be better understood from a reading of the following specification when read in connection with the accompanying drawings in which:

FIG. 1 is a top plan view of a preferred embodiment of this invention;

FIG. 2 is a bottom view thereof; and

FIG. 3 is a cross sectional view thereof taken along line 3 3 of FIG. l.

Description of preferred embodiments With reference now to the drawings, a preferred embodiment of the weatherproof expansion joint construction is illustrated at 10 in FIGS. 1-3. The expansion joint construction comprises a first anchor strip 11, a second anchor strip 12, an integral, extruded plastic sheet 13 extending therebetween and an underlying foam panel 14.

The anchor strips 11 and 12 are identical and only one yanchor strip 11 will be fully discussed. The anchor strip is preferably an extrusion of aluminum which may be provided in any desired length and preferably a length of l0 feet. The anchor strip 11 has a flat ange 15 with an inner edge 16 defined by a seat 17 extending along the length thereof and having lan opening 1 8` between lips or arms 19 and Z0 preferably defining a generally circular cross section as best shown in FIG. 3. The flat flange 15 is preferably provided with break-off indentations 21 running parallel to the edge 16 and suitable nail down holes 22 for attaching the anchor strip to one side of a curb or other joint portion to be weatherproofed. Conventional flashing and asphaltic materials may be provided over the flat flange 15 to insure watertight joints as is well-known in the art.

While each anchor strip is preferably made of an aluminum extrusion, other integral extrusions of metals such as stainless steel or copper or alloys thereof with or without aluminum can be used. In some cases, rigid plastics such as thermosetting plastics including urethanes, rigid vinyls, urea-formaldehyde, acrylates and the like can also be used for the anchor strips.

In the preferred embodiment, when aluminum is used for the anchor strip, it is preferably formed With flange 15 having a thickness of about 0.05 inch but may range from .005 inch to .375 inch. The outer diameter of the seal 17 is preferably `about 0.304 inch with an inner diameter of about 0.160 inch.

The plastic sheet 13 preferably defines parallel enlargements 24 and 2S seated in seats 20. The material of the plastic sheet is preferably a polyvinyl chloride plastic having some resiliency and formed into van arch as shown to aid in permitting expansionmand contraction when the anchor strips are axed to opposing edges or curbs asin a building construction. Other plastics such as neoprene, and butyl rubber can be used for the sheet 13. The polyvinyl plastic sheet preferably has a uniform thickness in the range of from .005 inch to .5 inch and acts to prevent entrance of water vapor or liquid through the seal from top to bottom thereof as shown in FIG. 3 and vice versa.

The enlargements 24 and 25 are elongated and continuous as are the seats 20 and are preferably of a diameter such that they can be resiliently compressed to pass into the open lips of the seat prior to mechanica'l compression of the seat and be firmly held by compression of the seat as will be described. In some cases, the cross section of the enlargements can be triangular, hex-shaped or have other geometric configuration. Preferably in all cases, the seat 17 defines a cross section corresponding to the cross section of the enlargements.

The seat of each anchor strip is compressed in a conventional swaging operation along its entire length so that the opening 18 formed by the lip ends does not substantially compress the flat thickness or web portion of the sheet 13 but does compress the enlargements to form a watertight seal therewith. FIG. 3 indicates the left-hand seat prior to swaging and the right-hand seat after swaging with enlargement 24 resiliently compressed.

The particular plastic used for the integral extrusion 13 having the enlarged ends is preferably polyvinyl chloride because of its known excellent resistance to aging and normal atmospheric conditions as well as its low -water vapor transmission properties. However, other plastic materials such as neoprene, polypropylene, polyethylene, polyvinyl materials, butyl rubber and the like may also be used.

Preferably a foam backing 14 in the form of an arch is adhered to the sheet 13 along its entire length, The foam is preferably a polyurethane having a width of 3 inches to 18 inches depending upon the width of the sheet 13 and the opening in the wall or roof and a minimum thickness of 1/2 inch. Any conventional foam backing may be used. The purpose of the foam is to provide some body to the joint and sustain the `arch in the shape shown while permitting expansion and contraction of the expansion joint construction. `Conventional adhesives can be used to adhere the foam to the polyvinyl chloride sheet 13. Polyurethane foams and other plastic foams such as polyethers, polyesters and vinyls can be used. It should be understood that in some applications, the foam backer can be eliminated. Preferably the foam used has a density of from 1 lb./cu. ft. to 5 lbs./cu. ft.

In a specific example of this invention, sheet 13 is -made of integral, extruded, virgin polyvinyl chloride having a sheet thickness of 0.060 inch, a length of feet, a width of 4 inches with integral 0.125 inch diameter enlargements 24. A 11/2 inch thick flexible polyurethane foam is adhered to the polyvinyl chloride sheet forming an arch. Anchor strips 11 and 12 comprise aluminum extrusions with the seats 20 being swaged about the enlargements to an inside diameter of 0.12() inch and with the opening 18 not compressing the sheet 13, The original diameter of the enlargements 24 is compressed slightly to provide a weatherproof seal between the anchor strips and plastic sheet.

When the above-described expansion joint construction is utilized to cover a span between a 2 inch opening defined by a curb in a roof construction, a long life advantageous weatherproof seal is obtained. Expansions and contractions of the joint construction as by move- -ment of the anchor strips toward and away from each other in `amounts at least as great as 2 inches on smaller cross sections and 6 inches on larger cross sections are easily provided for with no resultant leakage problem.

While a specific embodiment of this invention has been shown and described, it should be understood that many modifications thereof are possible. For example, the specific shape of the enlargements 24 and the corresponding seat 20 can vary although a neck section is always provided to mechanically assist in the strength of the joint formed between the sheet 13.and the anchor strips. No adhesives are used thereby avoiding any problems due to adhesive aging and application in construction. The specific shape of the anchoring strips may vary to provide for circular joint sealing and the like. Various joints and T arrangements can be provided where seals cross one another as is known in the art. The specific dimensions given are given for illustrative purposes and it is obvious that various dimensions may be used depending upon the size of the joint to be protected by the expansion joint construction of this invention. ln all cases, it is important that the flat body of the sheet be substan-y tially uncompressed while the enlargements are resiliently compressed by the swaging operation to prevent excessive stress in the joint construction yet provide good sealing properties.

What is claimed is:

1. A weatherproof expansion joint construction for use in sealing joints comprising,

a first elongated anchor strip,

a second elongated anchor strip,

a plastic sheet defining n'rst and second elongated substantially parallel side edges and having a web spanning between said first and second anchor strips,

said first and second side edges each defining an integral elongated, continuous, resiliently compressible enlargement,

said first and second anchor strips each carrying an elongated continuous seat having opposed arms defining spaced apart lip ends with the seat of said first strip having a cross section such that the internal dimensions of said seat defined by said arms closely surround and are joined to said enlargement of said first side edge with said enlargement being resiliently compressed without compressing said web so that said lip ends are spaced apart a distance substantially equal to the thickness of said web at the juncture of said web and said enlargement, and the seat of said second strip having a cross section such that the internal dimensions of said seat defined by said arms closely surround and are joined to said enlargement of said second edge which is resiliently compressed without compressing said web so that said lip ends are spaced apart a distance substantially equal to the thickness of said web at the juncture of said web and said enlargement,

said seats being joined to said enlargements solely by continuous swaged mechanical bonds with the internal dimensions of each seat of said arms being less than the dimensions of said enlargements in their relaxed position.

2. A weatherproof expansion joint construction in ac cordance with claim 1 wherein said plastic sheet is polyvinyl chloride material and said anchor strips are each integral metallic strips,

said plastic sheet having a uniform thickness in the range of from .005 to .5 inch,

and said metallic strips having a thickness of from .005 to .375 inch.

3. A weatherproof expansion joint in accordance with claim 1 wherein said anchor strips are composed of aluminum.

4. A weatherproof expansion joint construction in accordance with claim 5 wherein said anchor strips each define parallel indentations on a bottom surface thereof.

5. A weatherproof expansion joint construction in accordance with claim 1 wherein said plastic sheet is in the form of ,an arch and is bound to an underlying foam plastic lying intermediate said seats.

6. A weatherproof expansion joint construction in accordance with claim 2 and further comprising,

said anchor strips each defining means for attachment thereof to a building construction and means for breaking off predetermined portions thereof,

5 6 and a foam plastic panel underlying and bonded to said 3,363,383 1/ 1968 La Barge 52-471 plastic sheet to support said sheet in the form of an Re. 25,733 2/ 1965 Patry 52--573 arch.

References Cited POREIGF PATENTS UNITED STATES PATENTS 5 567364 1957 Ita y' 2,226,886 12/1940 Willis 52-471 HENRY C. SUTHERLAND, Primary Examiner 2,354,485 7/ 1944 Slaughter 52--309 3,218,771 11/ 1965 Horn 52-98 U.S. Cl. X.R. 3,272,684 9/ 1966 Moore 52--309 52-394, 466, 573 3,300,913 1/ 1967 Patry 52-309 

